mv agusta 910 engine workshop manual

COLORE COPERTINA PANTONE BLU 289Ghiera, scritta ”MV AGUSTA BRUTALE 910 S” e ombra, argento lito

Workshop engine manual

MVAGUSTA BRUTALE 910 SMVAGUSTA BRUTALE 910 S

© 2005The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A.

Part. N° 8A00A6440 - Edition N° 1Printed – December 2005

Workshop engine manual

MVAGUSTA BRUTALE F4 910 S

- 2 -

Statement

This manual, to be used by the MV Agusta authorised workshops has been realised with thepurpose of assisting authorised personnel in maintenance and repairs operations of themotorcycle. The knowledge of technical data herein noted, determines the complete profes-sional training of the technician.With purpose of making the reading of this manual immediately comprehensible, the para-graphs have been aligned with detailed illustrations that highlight the argument dealt with.

Useful advice

To prevent any problems and to reach an excellent final result, MV Agusta recommendskeeping to the following guidelines:

- In the case of an eventual repair, evaluate the client’s impressions who states that thereis an abnormal functioning of the motorcycle and to formulate the right questions toclarify the symptoms of the problem.

- Clearly diagnose the cause of the abnormality. The basic fundamental theories can beabsorbed by reading this manual that must necessarily be integrated to the personalexperience and the participation of training courses that are periodically organised byMV Agusta.

- Rationally plan the repair to avoid slack periods, e.g. the collection of spare parts, thepreparation of tools and equipment, etc.

- To reach the part to be repaired limiting the work to the essential operations.With regards to this, a valid help would be to consult this manual with regards to thesequences of removal demonstrated in this manual.

Informative noteMV Agusta S.p.A. is committed to a policy of continuous improvement of their products. Forthis reason, there could be slight differences between that which is written here and themotorcycle on which repairs and/or maintenance are about to be carried out. MV Agustamodels are exported to many countries where different norms in relation to the highwaycode and homologation procedures are valid. Hoping that you will comprehend these prob-lems, MV Agusta S.p.A. reserves the right to make modifications to its products and tech-nical documentation at any moment and without prior announcement.

Respect and defend the environmentEverything that we do has repercussions on the entire planet and its resources.MV Agusta, wanting to protect the interest of the people, would like to make the client andthe technicians of the technical assistance centres aware and to adopt modalities of use ofthe motorcycle and the disposure of its parts in full respect of the norms in force in terms ofenvironmental pollution, disposal and the recycling of waste.

Freni

- 3 -

A

B

General Index

GENERAL DESCRIPTION........................................................................................

ENGINE ....................................................................................................................

- 1 -

General description

A

SECTION ARevision 0

- 2 -

General description

A SUMMARY

HOW TO CONSULT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

THE PURPOSE OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 3

GLOSSARY AND SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 4

RIGHT HAND AND LEFT HAND STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 6

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 7

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 9

OPERATIVE TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE 10

General description

HOW TO CONSULT THIS MANUAL

Order of the subjects

This manual is divided into chapters that deal with thesub-groups of the motorcycle.To quickly find the chapter required, the pages of eachchapter are marked with a reference mark aligned tothe relative item in the general index.

- 3 -

A

EXAMPLE

Steering pin tighteningScrew in the steering pin flange ring, without tighten-ing.This operation must be done manually.Check that the steering base is at the end of its travel,to the right.Using the special tool N. 800091645, tighten the ring(1) by rotating it 10° calculated approximately as onethird of the movement between the two holes of thering (2) of the steering head (see the figure).

2

1

Display of the operations

The operations of disassembly, assembly, removal and control are presented with the help of illustrations (designs andphotographs).The illustrations contain symbols that indicate the procedure, special tools and other information. See the symbols listsfor their significance.The procedures are described step after step.

PURPOSE OF THE MANUAL

Principally, this manual has been written for MV Agusta dealers and qualified mechanics.It is not possible to document all the knowledge necessary for a mechanic in a manual. Those who utilise it must havea basic knowledge of mechanical concepts and the inherent procedures in the techniques of repairing motorcycles.Without this knowledge, The maintenance and repair operations can render the motorcycle unsafe for use.

Updates

MV Agusta S.p.A. is committed to a policy of continuous updating of the models produced. The modifications and sig-nificant changes to the specifications and the procedures will be communicated to the official dealers and will appearin future editions of this manual.

All information, instructions and technical data included in this manual are based upon information on the productupdated at the moment of going to print. MV Agusta S.p.A. reserves the right to carry out changes at any moment with-out prior notice and without incurring any obligation.

10°

- 4 -

General description

A GLOSSARY AND SYMBOLS

During this kind of proce-dure inflammable vapoursmight develop and metallicparts might be expelled athigh velocity. Thus, it is nec-essary to:- work far from exposed

flames and sparks;- wear protective clothing;- wear protective eye-

glasses.

ATTENTION

In case it should be neces-sary, due to wear, to substi-tute a particular, relative toa cylinder, we strongly sug-gest that you check and ifnecessary, substitute thesame particular in all of thecylinders for more satisfyingresults.In particular, we recom-mend that at the same timeyou substitute:- pistons with relative elas-

tic bands and piston pins;- valves with relative

springs, semi-cones,disks and grazings;

- Valve guides with relativevalves, springs, semi-cones and grazings;

- bed bearing;- whatever else undergoes

uniform wear, aside fromthe position of the relativecylinder.

In order to allow the motorto function under the bestconditions, it is necessarythat all of the couplings arewithin the accepted toler-ances established. A tightcoupling, is in fact, causefor seizure as soon as theorgans in motion begin toheat, while a loose cou-pling is cause for vibrationswhich accelerates wear onthe particulars in motion.

N.B. All of the countersigns indicting right,left, superior, inferior, front and back,refer to the motor-bike in the normaldirection of march.

WARNING

The motor supports numbering of thecylinders and of the attached compo-nents, increases moving from lefttowards right in regards to the directionof march.

N.B.

WARNING

This symbol indicates the "procedure tobe carried out with the motor removedfrom the motor-bike".

This symbol indicates "the proceduresto be carried out with an empty coolingcircuit".

Tighten to the specified torque.

Tolerance or limit of use.

Utilise the tester.

Utilise a specific tool or equipment forthe correct carrying out of the operationdescribed.

General description

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A

Use the recommended oil.

Use the recommended grease.

Use the recommended brake fluid.

Use the recommended suspension fluid.

Use the recommended coolant.

Use the recommended thread-lockingfluid.

Use the recommended sealant.

Use the recommended adhesive.

Carry out accurate cleaning.

Use new components.

Substitute the component.

Do not leave litter about.

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General description

A

Left side

Left side

Right side

Right side

Cylinder 3

Cylinder 4 Cylinder 1

Cylinder 2

RIGHT HAND AND LEFT HAND STANDARD

To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of themotorcycle and the engine against which are indicated the right and left sides.

General description

- 7 -

ASAFETY

Carbon Monoxide

• Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of con-sciousness and death.

• If it is necessary to switch on the engine, check that the environment is well ventilated. Never switch on the enginein an enclosed environment.

• Switching on the engine can only be carried out in an enclosed environment when there are the appropriate devicesfor the evacuation of exhaust gases.

Petrol

• Petrol is extremely inflammable and under certain conditions can be explosive.• Keep sources of heat, sparks and flames away from the work area.• Always work in a well-ventilated area.• Never use petrol as a cleaning solvent. Generally, avoid handling it unless it is absolutely necessary.• Do not use petrol for cleaning components by using compressed air.• Keep petrol out of reach of children.

Engine oil

• Engine oil can cause skin illnesses if in constant and long contact with the skin. • If the skin comes into contact with engine oil, wash the parts affected as soon as possible with soap and water.• If engine oil comes into contact with the eyes, rinse abundantly with water and seek medical attention.• If engine oil is swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Transport

the injured person immediately to hospital.• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is necessary to be

equipped to deal with the collection of used oil in respect of the norms in force.• Do not dispose of used oil in the environment.• Keep used oil out of the reach of children.

Engine coolant

• Under certain situations, the ethylene glycol contained in the engine coolant is inflammable and its flame is invisible.Ethylene glycol would cause serious burns if ignited because it is invisible.

• Avoid bringing the engine coolant into contact with hot parts. Such parts could be sufficiently hot to ignite the coolant.• The engine coolant (ethylene glycol) can cause irritation of the skin and is poisonous if swallowed.• If the engine coolant comes into contact with the skin, immediately remove any contaminated clothing and wash with

soap and water. If it comes into contact with the eyes, abundantly rinse with clean water and immediately consult adoctor. If swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs. Administer cleanwater and transport the injured person immediately to hospital and show the product to the doctor.

• If exposed to high concentrations of vapour, transport the injured person to a non-poisonous atmosphere and if nec-essary call a doctor.

• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be vio-lently ejected and therefore provocate burns.

• The engine coolant contains dangerous and poisonous substances and is therefore dangerous for the environment.To substitute used engine coolant, it is necessary to be equipped to deal with the collection of used oil/of used enginecoolant in respect of the norms in force.

• Do not dispose of engine coolant in the environment.• Keep engine coolant out of reach of children.

ATTENTION The information contained in this paragraph is fundamental so that the operations carriedout on the motorcycle can be conducted with minimum risk to the mechanic.

- 8 -

General description

Brake fluid

• Brake fluid is extremely corrosive.• Avoid any contacts with the eyes, skin and the mucous membrane.• If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap

and water.• If brake fluid comes into contact with the eyes, abundantly rinse with water and call a doctor.• If swallowed, do not provocate vomiting to avoid aspiration of the product into the lungs. Immediately call a doctor.• Take the injured person immediately to hospital, if he has breathed brake fluid into the lungs.• In the case of exposure to high concentrations of vapour, move the injured person to a non-poisonous atmosphere

and if necessary call a doctor.• In the case of accidental contact, rinse abundantly with water and call a doctor.• Keep brake fluid out of reach of children.

Thread-locking fluid

• As it is not classified as dangerous, the prolonged contact with the skin, particularly with regards to abrasions canprovocate sensitiveness and dermatitis. In the case of contact with the skin, rinse abundantly with running water.

• Move the injured person into the open air and call a doctor if the injured person feels ill after having breathed in theproduct.

• In the case of contact with the eyes, rinse abundantly with water for at least 15 minutes.• If the thread-locking fluid has been swallowed, drink an abundant quantity of water or milk. Do not provocate vomit-

ing to avoid the aspiration of the product into the lungs. Immediately call a doctor.• Keep out of reach of children.

Nitrogen - rear shock absorber

• The rear shock absorber contains nitrogen under pressure.• Before disposing of used shock absorbers, discharge the nitrogen via the depressurising valve.• Utilise only nitrogen to pressurise the shock absorber. The use of unstable gases can cause explosions that could

cause burns.• Do not place the shock absorber near to flames or sources of heat as this could cause explosions with consequent

burns.• Keep out of reach of children.

Battery

• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging, ade-quately ventilate the environment.

• The battery contains a solution of sulphuric acid (electrolyte).• Sulphuric acid is corrosive and it destroys many materials and clothing. On contact with small quantities of water it

generates a violent reaction that manifests itself by creating large quantity of heat and spurts of hot acid. Sulphuricacid attacks many metals thereby liberating hydrogen: an inflammable gas that forms an explosive mixture whenmixed with air.

• Contact with sulphuric acid can cause burns. In the case of contact, remove immediately all contaminated clothingand wash the skin with abundant quantities of water. Take the injured person to hospital if necessary.

• In the case of contact with the eyes, rinse immediately with abundant water. Call a doctor and continue with the treat-ment until the doctor arrives.

• If the electrolyte is swallowed, rinse the mouth with water without swallowing. Take the injured person immediatelyto hospital and explain to the doctor there what the injured person has swallowed.

• The battery contains dangerous substances that are poisonous for the environment. It is necessary to be equippedto dispose of this product in respect of the norms in force.

• Do not dispose of used batteries in the environment.• Keep out of reach of children.

Hot parts

• The engine and the exhaust system become very hot and maintain this temperature for some time after the enginehas been switched off. Wait for these parts to cool down before handling them or working on the motorcycle near tothem. Use protective gloves.

A

General description

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A

SUMMARY OF EACH CHAPTERGENERAL INDEX

HOW TO CONSULT THIS MANUAL ................................................................................................................PAGE 3

THE PURPOSE OF THIS MANUAL..................................................................................................................PAGE 3

GLOSSARY AND SYMBOLS ...........................................................................................................................PAGE 4

RIGHT HAND AND LEFT HAND STANDARD..................................................................................................PAGE 6

SAFETY .............................................................................................................................................................PAGE 7

OBSERVATIONS ..............................................................................................................................................PAGE 9

INDEX.................................................................................................................................................................PAGE 9

OPERATIVE TECHNICAL SPECIFICATIONS..................................................................................................PAGE 10

SUMMARY

General description

GENERAL DESCRIPTION

ENGINE .................

General Index

INDEX

WARNING

The information contained in thisparagraph is important so that theoperations carried out on the motor-

cycle can be conducted without damaging the motorcycle.

• Thoroughly clean the motorcycle before disassembling it.

• During disassembly, clean all parts and place them in con-tainers respecting exactly the order of disassembly.

• Always use the special utensils where necessary andeach time where prescribed.

• Always use adhesives, sealants and lubricants where pre-scribed. Respect the instructions about their technicalcharacteristics.

• Always substitute parts such as gaskets, O-rings, securitywashers with new parts.

• Slackening or tightening nuts or screws, always start withthose of a greater dimension or from the centre. Alwaysrespect the torque values indicated.

• Utilise only MV Agusta spare parts.

WARNING

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General description

A

2) Engine registration number

1) Frame registration number

3) Homologation date

OPERATIVE TECHNICAL SPECIFICATIONS

MOTORCYCLE IDENTIFICATION

The registration number of the motorcycle is stamped on the right side of the steering head.

The engine registration number is stamped on the upper engine casing, near the forks.

Below is an example of the designation of the frame registration number:

ZCG F4 11 ?? ? V ??????

Manufacturer identificationVehicle model

VersionMY

EstablishmentProgressive frame number

B

- 1 -

Engine

SECTION BRevision 0

- 2 -

Engine

B

SUMMARY

TABLE OF CLAMPING TORQUES ..........................................................................................................PAG. 3

PLANNED MAINTENANCE SCHEDULE ..................................................................................................PAG. 5

THROTTLE BODY ADJUSTMENT AND TUNING........................................................................................PAG. 13CYLINDER HEAD ......................................................................................................................................PAG. 20

DISTRIBUTION CONTROL UNITS............................................................................................................PAG. 24

CYLINDER AND PISTON GROUP ............................................................................................................PAG. 44

CLUTCH ....................................................................................................................................................PAG. 50

GEAR AND GEAR CONTROL ..................................................................................................................PAG. 57

ELECTRICAL COMPONENTS ..................................................................................................................PAG. 64

OIL PUMP ..................................................................................................................................................PAG. 66

WATER PUMP............................................................................................................................................PAG. 68

STARTING..................................................................................................................................................PAG. 72

MOTOR SHAFT..........................................................................................................................................PAG. 74

BEDPLATE ................................................................................................................................................PAG. 76

CAPS ..........................................................................................................................................................PAG. 77

LUBRICATION COMPONENTS: OIL TUBING SUPPORT PLATE ..........................................................PAG. 86LUBRICATION COMPONENTS: OIL FILTER SUPPORT ........................................................................PAG. 87REPLACEMENT OF OIL FILTER ..............................................................................................................PAG. 90LUBRICATING COMPONENTS: OIL RADIATOR ....................................................................................PAG. 93

B

Engine

- 3 -

TABLE OF CLAMPING TORQUES

DESCRIPTION N·m Thread blockers

HEAD

Camshaft and gear screws 21 strong

Sliding block distribution screws 8 medium

Stand screws 12

Valve cap screws 8

Chain tightening screws 8

Chain tightening cap 12

CLUTCH

Clutch nut 140 medium

Disk thrust plate screws 10

GEAR SHIFT

Pinion nut 140 medium

Gear selection drum tightening screws 25 medium

M6 gear control screws 8 medium

BEDPLATE ACCESSORIES

Alternator tightening screws 25

Motor starter tightening screws 10

Water pump tightening screws 8

Neutral switch screws 10

FREE WHEEL STARTING

Flexible coupling generator control screws 25 medium

Flexible coupling nut 55 strong

Flange tightening screws together with free wheel 10 medium

OIL CUP

Oil cup tightening screws 10

TIGHTENING TORQUES: CONVERSION FACTORSTo convert a tightening torque, refer to the following table.

N·m Kg·m ft·lbs

N·m ------ 0,10197 0,7375

Kg·m 9,807 ------ 7,233

ft·lbs 1,3559 0,13826 ------

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Engine

B

CLAMPING TORQUES TABLE

DESCRIPTION N·m Thread blockers

BEDPLATE

Clutch cap M6 screws 8

M6 bearing clamp screw 12 medium

Extractable gear change cap M8 screws 25

M6 torque screws 10

M8 torque screws 25

Plate screws for oil radiator connectors 10

Support screws for oil filter 40

Inlet/outlet connectors for radiator oil 30 medium

CONNECTING ROD

Cap screws (*)

(*) See fitting notes

Engine

- 5 -

B

PLANNED MAINTENANCE SCHEDULEThe following diagram shows the recommended planned maintenance intervals. Periodic maintenance is essen-tial to keep the vehicle in perfect running order and to ensure optimum cost efficiency.

Use shorter maintenance intervals if the vehicle is used in particularly harsh conditions.

Let us help protect the environmentEverything we do affects the entire planet and its resources. To protect the common interest, MV Agustaurges its customers and service operators to use the vehicles and dispose of their components in com-pliance with applicable regulations on environmental pollution control, waste disposal and recycling.

Scheduled maintenance tables

WARNING

0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery

Description Procedure

Motor oil Substitution ● ● ● ● ● ● ●

At least every year

Motor oil filter ● ● ● ● ● ● ●

Each time engine oil is renewed

Cooling liquid Check / Top up ● ● ● ● ● ● ● ●

Substitution Every two years

Cooling system Check for leaks ● ● ● ● ● ● ● ●

Electric fan Check operation ● ● ● ● ● ● ● ●

Valves Check / Regulation ● ● ● ●

Distribution chain Check ● ● ●

Substitution ●

Mobile distribution block Check / Substitution ● ● ●

Substitution ●

Every time timing chain is replaced

hain tightening block Check / Substitution ● ● ●

Spark plugs Check / Substitution ● ● ● ●

Substitution ● ● ●

Fuel filter Substitution ● ● ●

Throttle body Check / Regulation ● ● ● ● ● ● ●

Air filter Check / Substitution ● ● ● ● ● ●

Brakes and clutch liquid Level check ● ● ● ● ● ● ●

Substitution ●

At least every two years

Brakes / Clutch Check operation ● ● ● ● ● ● ● ●

Plant chexk ● ● ● ● ● ● ●

● ● ● ● ● ● ● ●

Prake pads Check / Substitution ● ● ● ● ● ● ●

( front + rear )

Fuel lines Check for defects and leaks ● ● ● ● ● ● ●

Substitution At least every 3 years

Throttle control Check operation ● ● ● ● ● ● ● ●

Verify/adjust play ● ● ● ● ● ● ● ●

Starter control Check operation ● ● ● ● ● ● ● ●

fFrequency Km (mi)

Coupon A B C D E F G

Substitution(Use only MV Agusta originaloil filter)

Cleaning of contact lever /pump piston area

- 6 -

Engine

B

0 1000 6000 12000 18000 24000 30000 36000(600) (3800) (7500) (11200) (14900) (18600) (22400)

Pre-delivery-

Description Procedure

Check / Regulation ● ● ● ● ● ● ● ●

Check / Regulation ● ● ● ● ● ● ● ●

Drive chain Lubrification ● ● ● ●

Substitution ● ● ●

Check ● ● ● ●

Pinion / Stop washerSubstitution

● ● ●

Every time drive chain is replaced

Check ● ● ● ●

Ring gearSubstitution

● ● ●

Comunque ad ogni sostituzione della catena di trasmissione

Sprocket elastic coupling Check ● ● ●

Head tube ring nut Check / Regulation ● ● ● ●

Steering bearingsCheck / Regulation ● ● ● ●

Lubrification ●

TyresCheck pressure ● ● ● ● ● ● ● ●

Check wear ● ● ● ● ● ● ●

Wheel rim Visual check● ● ● ● ● ● ●

Every time tyres are replaced

Check● ● ● ● ●

Front wheel bearings Every time tyres are replaced

Substitution ●

Side stand Check operation ● ● ● ● ● ● ● ●

Side stand Check operation ● ● ● ● ● ● ● ●

switch ● ● ● ● ● ● ● ●

Rear wheel hubCheck / ● ●

Substitution / ●

Big fork bearings Check / lubrification ●

Big fork chain shoes Check / substitution ● ● ● ● ● ● ●

Frame plate chain shoes Check / substitution ● ● ● ● ● ● ●

Rear damper Check / Regulation ● ● ● ●

Front fork oil Substitution ●

Battery connections Check and cleaning ● ● ● ● ● ● ●

Electric system Check operation ● ● ● ● ● ● ● ●

Meter assy. combination Check operation ● ● ● ● ● ● ● ●

Lights / visual signals Check operation ● ● ● ● ● ● ● ●

Claxon Check operation ● ● ● ● ● ● ● ●

Front head lightCheck operation ● ● ● ● ● ● ● ●

Regulation Every time vehicle geometry is altered

Starter switch Check operation ● ● ● ● ● ● ● ●

Locks Check operation ● ● ● ● ● ● ● ●

Tightening of screws and nuts Check / Tighten ● ● ● ● ● ● ● ●

Hose clamps Check / Tighten ● ● ● ● ● ● ● ●

General lubrication ● ● ● ● ● ● ● ●

General test ● ● ● ● ● ● ● ●

Transmissions and flexible controls

A B C D E F G

needle bearinglubrfication

needle bearinglubrfication

Frequency Km (mi)

Coupon

Cleaning of contact leverarea with side stand

Engine

- 7 -

B

Description Recommended product Specifications

Engine lubrication oil AGIP RACING 4T 10W/60 (*) API SJ SAE 10W/60

Ethylene glycol

Cooling liquid AGIP ECO - PERMANENT diluted with 40 per cent

distilled water

Clutch and brake fluid AGIP BRAKE FLUID DOT4 DOT4

Chain oil MOTUL CHAIN LUBE ROAD –

Table of lubricants and fluids

* : MV Agusta recommends purchasing the product from its authorized dealers. The engine oil AGIP Racing 4T10W/60 has been specially designed for the F4 engine. Should this lubricant be unavailable, MV Agusta recom-mends using fully synthetic oils complying with or exceeding the following spe-cifications:

– API SJ– ACEA A3– JASO MA– SAE 20 W-50 o 10 W-60

The above specifications are to be found, alone or in combinationwith others, on the lubricating oil container.

Motor oilSAE 10 W-60

API SJACEA A3JASO MA

NOTE

- 8 -

Engine

B

ITEM

VALVESØ Sealing external diameter

Exhaust..............................

Inlet....................................

Sealing face thickness......

Stem-guide clearanceExhaust..............................

Inlet....................................

Ø Guide internal diameter.......

Valve stemExhaust..............................

Inlet....................................

Valve springInternal...............................

External..............................

Valve-cam clearanceExhaust..............................

Inlet....................................

STANDARD

24,6 mm

28,6 mm

1 mm

0,02 ÷ 0,04 mm.........................

0,01 ÷ 0.03 mm.........................

4,5 mm...........................

4,475 ± 0,005 mm.....................

4,485 ± 0,005 mm.....................

33,8 mm....................................

37,9 mm....................................

0,20 ÷ 0,29

0,15 ÷ 0,24

WEAR LIMIT

Coupling : 0,10 mm

0,08 mm

4,55 mm

4,445 mm

4,455 mm

33,3 mm

37,4 mm

+0,30

+0,30

+0,2-0,3

+0+0,012

B

Engine

- 9 -

ITEM

CYLINDER AND PISTONPiston ovalization...................

Piston-cylinder play................

Piston-pin play........................

Pin-foot connecting rod play.....

Segment thickness

1st......................................

2nd......................................

Oil scraper.........................

Maximum segment-cylinder play

1st......................................

2nd......................................

Scraper.............................

CLUTCH

Disk thickness........................

Springs...................................

STANDARD

...................................................

0,038 ÷ 0,067 mm

0,004 ÷ 0,012 mm

0,015 ÷ 0,032 mm

0,8 mm...........................

0,8 mm...........................

1,5 mm...........................

0,2÷ 0,4 mm.............................

0,2 ÷ 0,4 mm.............................

0,2 ÷ 0,7 mm.............................

3 mm.........................................

..................................................

WEAR LIMIT

0,015 mm

0,10 mm

0,03 mm

0,06 mm

0,75 mm

0,75 mm

1,38 mm

0,6 mm

0,6 mm

1 mm

2,8 mm

57,9 mm

-0,01-0,03

-0,03-0,08

0-0,02

- 10 -

Engine

B

ITEM

GEAR SHIFT

Gear fork-groove pivot play..........

Drum pit width.........................

Ø fork pivot.............................

Minimum idle gear axial play.................................

Maximum gear fork play........

Gear limit

Primary...............................

Secondary..........................

Fork selection gear limit

Primary (5a - 6a)..............

Secondary (1a-2a, 3a-4a).

Fork – pit play.........................

BEDPLATE – DRIVE SHAFT

Bed bearing functioning play.......................

Connecting rod bearing Functioning play......................

Drive shaft axial play...............

STANDARD

0,35 ÷ 0,15 mm.........................

7,05 ÷ 7,15 mm.......................

6,8 ÷ 6,9 mm.............................

0,10 mm

...................................................

...................................................

...................................................

...................................................

...................................................

0,2 ÷ 0,3 mm

0,012 ÷ 0,038 mm.....................

0,036 ÷ 0,061 mm.....................

0,2 mm

WEAR LIMIT

0,65 mm

7,35 mm

6,7 mm

0,7 mm

5,6 mm

4,6 mm

4,65 mm

3,65 mm

0,7

0,06 mm

0,08 mm

Engine

- 11 -

B

Cleaning the partsAll of the parts must be cleaned with specialbiodegradable solvents and dried with compressed air.Proceed with the cleaning process of all the partsbefore disassembling them as well as after the partic-ular parts have been disassembled. Clean each parteven before reassembling.

ConnectionsIn order to allow the motor to function in the best con-ditions it is absolutely necessary that all of the connec-tions meet the standards established by the manufac-turer. A connection with reduced standards couldcause seizing, while a connection with excessive toler-ation causes vibrations which accelerate the wear ofthe components.

General norms for assembling the partsFor reassembling invert the disassembling procedure,paying careful attention to the specified procedures.Gaskets, oil spill protector, metallic locks. Tighteningrings in deformable material and self blocking nutsmust always be substituted.The bearings are dimensioned for a determined num-ber of working hours. Substitution is therefore recom-mended in consideration of the difficulty in checkingwear. The above mentioned is in addition suggestedfor dimensional controls of the single componentsmentioned in the relative paragraphs. It is absolutely necessary to carefully clean all of thecomponents; the bearings and all of the other partssubject to wear must be lubricated with motor oil beforereassembling. Nuts and screws must be locked to thepre established torques.

Following are the descriptions of the disassembling,revision and reassembling procedures of the variousparts and sub parts constituting the motor, in the final-ized sequence of a completely disassembled motor.

Disassemble the motor from its frame as described inthe relative paragraph;Drain the oil from the oil cup;Remove the spark plugs covering the openings withclean rags to avoid small objects (rings, etc.) fromfalling into the motor.

Measuring compression in the cylinderThe following tools are necessary in order to carry outthis procedure:Spark plug key: n° 800089013 Compression measurerAdapter for the compression measurer.

A) Heat the motor to the usual functioning temperature (of regime);

B) Switch off the engine, remove the tank, air boxand sparkplugs;

C) Measure cylinder compression.

Drag the motor into rotation by means of the startingmotor with the butterfly valve completely open until thecompression measurer indicator (compessionmeter)no longer rises; the compression measurementobtained is the maximum.

Be sure the battery is completely charged.

- Repeat the procedure for the other cylinders.

N.B.: If the compression in the cylinder is lower thanthe minimum value of the reported range, check thefollowing points:

A) carbon deposits on the walls of the combustionchamber and on the piston ceiling; B) lthe head gasket is not of the correct measure-ments;

N.B.: If the compression in the cylinder is lower thanthe minimum value of the reported range, check thefollowing points:

A) The seat of one or more valves is damaged andthe valves do not maintain the compression pres-sure;B) One or more valves have null functioning play;C) The piston, cylinder play is excessive;D) The cylinder head is twisted and/or the head gas-ket is damaged;E) Excessive play between ring and cable.

- 12 -

Engine

B

NOTE

Before carrying out the compression trial,accurately check the battery tension sincethe compression value which appears isquite influenced by the rotation velocity ofthe motor, and consequently by the bat-tery tension.

NOTE

Cylinder compression control (280 rpm-min.)Motore Tipo Press. Min (bar) Press. Max (bar)

910 S 7,5 14

Engine

- 13 -

B

THROTTLE BODY ADJUSTMENT AND TUNING(Tickover check, CO synchronisation and check)

Check and adjust ➝ First 1000 kilometres andthen every 6000 kilome-tres

The throttle body adjusting should be performed star-ting the engine of the motorcycle, therefore you shoulduse a flue gas exhauster in order to not saturate theenvironment with burnt gas.

The following described operations are fundamentalfor the correct functioning and the maximum perfor-mance of the engine.

When carrying out operations on throttle bodies, it isadvisable to remove certain parts of the bodyworksuch as:

• Passenger seat• Rider seat• Tank side panels• Ignition switch cover• Fuel tank

Attention: before adjusting the throttle body verifyaccurately:- the absence of any cracks or damages on the pipesto check the depression;- the absence of gas leakages from drain pipes joint;- that the fuel pipe unions are not buckled and crushed.

You should provide the motorcycle with tank placed onan auxiliary support. Therefore you should connect thehydraulic extensions of the fuel pipes and the electricalextension for feeding fuel pump.

- 14 -

Engine

B

Verify the parameters of the injection-ignition systemby the MDST diagnosis software.

Connect the tool cable of the MDST diagnosis with the“Diagnostics” tap on the right side of the motorcyclenear the expansion tank of the coolant.

Start the MDST diagnosis software and go to the“Display instrument panel” screen.Set the ignition switch to ON.Select the “Connect” option from the toolbar. Now thesoftware displays the main operating parameters of theinjection-ignition system: verify that the temperatureand pressure sensors have coherent readings.

Engine

- 15 -

B

Check the throttle angle when the throttle is completelyclosed.

Huntings between 1.9° and 2.1° and between 2.3° and2.5° are allowed only if the engine is started.A value above 2.5° is not allowed.

If necessary adjust the throttle opening using only theappropriate screw on the throttle opening pulley.It is recommended not modify the throttle potentiome-ter position because the throttle has been set duringthe production to the optimal value.

Remove the sealing caps of the small tubes to checkthe vacuum pressure.The number of the cylinder to which the caps are con-nected is written on the caps.The small tubes for checking the vacuum pressure are

- 16 -

Engine

B

Connect the depression pipes with the vacuometercomplying with the match between the pipe and thecylinder which is connected to.

In order to perform the following operations, youshould provide with the specific tool kit for setting CO.

Specific tool:Part code 8000A4686

Remove the sealing caps of the CO drives placed onthe exhausts.Insert and screw the 2 probes registering CO inside thespecific tool kit (code 8000A4686).Assemble the 2 pipes with their Y union, also suppliedwith tool kit, code 8000A4686, on the probes registe-ring CO.Connect the Y union with a rubber pipe to the exhaustgas analyser.

Verify that the ignition switch is set to OFF.Disassemble the injection-ignition gearcase placed onthe air filter compartment unscrewing the four fixingnuts.Reset the earth bonding on the gearcase by using anut and a M6 screw (for the correct performance of theadjusting operations, it is important the gearcase isearthed).

Engine

- 17 -

B

Remove the seal plate and then the gearcase sealingcap.

The by-pass screws must first be adjusted as follows:

One and a half turns from the closed position

Start the engine and warm it up. During this phase youshould not accelerate because the high depressioncreated in the induction lines could pipe the mercuryfrom vacuometer.The engine rotation can be supported by using thestarter.The attainment of the correct thermal speed is given bythe intervention of the cooling fan.

- 18 -

Engine

B

Balance the pressures in the cylinders: the mercurycolumns must reach the same height.If all the parameters of the engine are set correctly, theposition of the adjusting screws should be between 1and 3.5 turns from the closed position.

The number of turns per minute must fall within the fol-lowing values: 1150 ÷ 1250 turns/min.

Check the CO value using the exhaust gas analyser.This value must be between the following values(inclusive):

This value must fall within the following values: 3.5% +0.5% (3.0% - 4%)

If the CO value does not fall into the establishedvalues, operate the trimmer inside the gearcase untilthe values fall into the tolerance range.

Engine

- 19 -

B

The attainment of the correct CO value could involve avariation of the engine speed at minimum.In this case you should operate the by-pass screwsagain to return the speed to the desired value and thenrepeat the trimmer adjustment.

After having finished the adjustment operations,perform in the order as follows:- assemble the rubber plug on the gearcase lower side;- apply a new seal plate;- assemble the gearcase on the air filter compartmentrestoring the earth bonding;- disassemble the exhaust gas probes and tighten thefixing screws;- restore the sealing caps of drives for checkingdepression;- reassemble tank, tank side panels, ignition switchcover, rider seat and passenger seat.

After reassembling all parts, carry out a final check toensure that everything has been correctly replaced.

- 20 -

Engine

B

OIL Apply motor oil

NO OIL Do not apply neither oil nor other types of substances

GR Apply grease

SS Apply silicone sealing

HSC Apply HSC Molikote

M Apply mastic for gaskets

CYLINDER HEAD

A B C* D E F G H I LN·m 12 8 45 8 36

Tighteningtorque

Thread blockers Medium Sealant

* See text.

Engine

- 21 -

B

Removal of Head groupRemove the eight tightening nuts (1) and remove thevalve cover (2) proceed carefully so as not to damagethe gasket (3).

When refitting, it is essential to apply silico-ne sealant as shown in the figure at thebeginning of the chapter.

On the left side of the motor remove, together with thegasket, the phonic wheel cover by means of the fivescrews.

3

2

1

- 22 -

Engine

B

Remove the oil tube adduction and the head situatedat the front of the motor, using the two tightening screwwith a T number 8 key.Working on the phonic wheel knot with a number 19mm bush key rotate the drive shaft up to the pointwhere the n° 1 piston is at MSP in burst phase.

In this position the T notch on the phonic wheel is linedup with the reference notch on the bedplate.

The cams relative to cylinder n° 1 converge upwards inthe symmetrical position as indicated in the figure.Beside, the reference notches on the control wheels ofthe camshafts are in horizontal position and positionedexternally.

Engine

- 23 -

B

Loosen the central screws of the chain tensioner distri-bution system. Remove the chain tensioner by meansof the two tightening screws.

First remove the 2 external stands (4 and 5) of thecamshafts by means of the four screws each internallyhexagonal.

At the same time remove the 2 internal stands (6 and7) placing attention on the thrust caused by valvesprings.

4 6 7 5

- 24 -

Engine

B

DISTRIBUTION CONTROL UNITS

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 21 8 8 12

Tighteningtorque

Tipo Thread blockers Strong Medium

NORDLOCK detail

Engine

- 25 -

B

In order to facilitate the detachment of the stands usea rubber hammer or delicately the end part of a flatscrewdriver.

Slightly rotate without force the unloaded end of thegearshaft shifting it from its slot; by doing so, the ten-sion on the distribution chain will loosen.

Release the distribution chain.First remove the unloaded end of the gearshaft. Fastenthe distribution chain with copper thread in order toretrieve it during the following procedure.

Remove the inlet end of the camshaft.

Remove the first link block for the distribution chain byusing the tightening screws.

In case it should be necessary to substitute the distrib-ution chain at the expected mileage (see the pro-grammed maintenance chart), it is advisable also tosubstitute the gears on the camshaft (INLETn°8000A3032 - EXHAUST n° 8000A3033).When refitting, thoroughly clean all surfaces.Position the timing gear so that the side that has recei-ved no thermal treatment (the one with no timingmarks) is in contact with the NL655-TYPE NORD-LOCK washers Part No. 8000A3486.When refitting, always replace the washers and fitthem as shown in the figure. Apply the threadlockingproduct STRONG THREAD BLOCKER on new screwsPart No. 8C0085071 and tighten at 21 N·m.During the operation, take special care in ensuring thatthe chain is not dislodged from its position.

NORDLOCK detail

- 26 -

Engine

B

Remove the 12 tightening nuts from the head begin-ning from the external ones proceeding towards theinternal ones, following the sequence indicated in thefigure.

On each encarcement there is a washer. Becarefully no to let it fall into the motor, youmay block the holes with clean rags.

Engine

- 27 -

B

Remove the head and place it onto a clear place

Remove the gasket which will be substituted duringreassembly.

Avoid placing the head upside down.

Inspection of the head groupRemove carbon deposits from the combustion cham-bers. Clean away eventual encrustments from thecanalizations of the cooling liquid. Check to be surethat are no crack and that the holding surfaces are freeof crevices, runs or any other kind of damage.Verify the planarity of the stroke surfaces.Verify the perfect state of the spark plug threads

- 28 -

Engine

B

Head assy assemblyTo execute this operation you need the following spe-cial tool:

A) n° 8000A3406 piston / cylinder plane distancemeasuring tool

Place the new gasket on the cylinder plane.The gasket is of the same thickness of the oneinstalled before if no parts replacement occurred.

If replacement is necessary you’ll need to measure thepiston / cylinder plane distance with the n° 8000A3406tool, tightening the head nuts at 12 N·m. The choice ismade following table below:

The cylinder base gaskets always have the samethickness (see table).

Distance between piston Type of gasket Codeand cylinder surface. (X)

-0,100; -0,250 mm 0,70 8B00A2300

-0,260; -0,410 mm 0,55 8A00A2300

-0,420; -0,570 mm 0,40 8000A2300

THICKNESS N° ITEM

0,38 mm 800087771

Do not position the feeler on the projectionon the piston top.

1-Gasket thickness2-Gasket codeNote: Fit the gasket with the inscriptions facing up.

EXHAUST SIDE

K12 Nm clamping

Engine

- 29 -

B

Fit the gasket with the inscriptions facing up and theprotrusion towards the march gear.Insert the centering bushes between the head and thecylinder. Positioning the head.Insert the washers on the encarcement if necessarywith the help of a screw driver to guide them onto theinternal encarcements.Lubricate with antibinding grease of the HSCMOLIKOTE type only on the nut threads.Do not apply grease on the encarcement threads,which must be well cleaned and degreased

Screw the bolts with a brugle key and press them at 35N·m.Tighten the bolts beginning with the internal onestowards the external ones following the outline indicat-ed in the figure at 45 N·m.

Retrieve the distribution chain.Insert the fixed sliding block with its screws and, afterhaving carefully degreased it, tighten it at a torque of 8N·m. with MEDIUM THREAD BLOCKER.

35 N•m

45 N•m

8 N•m

- 30 -

Engine

B

Continue with the setting as follows:be sure that piston n° 1 is the MSP in burst phase; inthis position “T” notch on the phonic wheel is in linewith the reference notch on the bedplate.Remove the copper thread from distribution chain,keep the chain tightened.

If the middle gears or motor shaft needreplacing, time the engine. Refer to theinstructions on the following page.

Engine

- 31 -

B

Check and placement of distribution chainAt each motor revision verify the wear state of eachtransmission distribution component. If the gear teethappear to be very worn substitute each piece.Substitute the chain at the foreseen mileage.

In case wear should result beyond the per-mitted allowance even of just one of the dis-tribution components, check them all and ifnecessary substitute them.

Rotate the drive shaft until the pellet on the phonicwheel tooth coincides with the notch on the bedplate,as shown in the following picture.Attention: the drive shaft in this position is NOT inthe MSP position.

Fit the distribution chain on the intermediate gear.Position the intermediate gear being careful that thepellet on the gear corresponds with the pellet on thebedplate, being careful that the drive shaft has notmoved from the position priorly described .Insert the intermediate gear rotation pin and tighten itwith the relative seeger.Without rotating the drive shaft check again to be surethat the pellet on the phonic wheel corresponds to thenotch on the bedplate.At this point, rotate the drive shaft and verify the cor-rect teeth gripping.Attention: the position relating to the balls will onlybe repeated after a few dozen turns of the engineshaft. However, this position does not need to befound for the correct assembling if the alignmentwas executed beforehand.

- 32 -

Engine

BPin number 24

Pin number 25

Pin number 1

Engine

- 33 -

B

Insert the inlet camshaft so that the phase notch on theconveyer wheel is parallel to the head plane and facingthe outside.Insert the exhaust camshaft with the notch placedbetween the 24th and 25th chain distribution gudgeon,beginning to count from gudgeon after the inletcamshaft notch.Check the correct position of all the O Rings under thehead stands.

NOTE: If the operation is performed with the engi-ne installed on the vehicle, lift the front wheel untilthe axis of the cylinders is in a vertical position.

Position the n°2 and n°3 stands, referring to the num-bers towards the inlet end;Position the n°1 and n°4 stands,Bring the screws together manually hexagonallyembedded.

Chain tensionerRemove the central screw-cap and withdraw the springand the pin.Remove the screws fixing the chain tensioner to thehead.Remove the chain tensioner.Disassembly the chain tensioner and check the correctworking of each part.The internal pin must run clearly and the inner springmust give a quick response.Replace the assembly in case of malfunction.If everything works properly lubricate the parts andinstall the assembly with the chain tensioner in the min-imum extension position (all in the main body)Install the chain tensioner body locking the 2 sockethead screws using a T wrench with a 8 N·m torqueInstall in this order: the pin in the spring, the spacer andthe screw cap.Lock the screw cap by hand till you feel the tensionerextend, then lock it with a 8 N·m torqueActing this way the chain tensioner is adjusted.

Before tightening stand screws be sure thatthe chain tensioner is assembled.

Progressively move the internal hexagonal screwsclose. Tighten the screws at a torque of 12 N·m.,always beginning from n°2 and n°3 stands.Check to be sure that the valve cap gaskets are ingood condition.Apply a layer of gasket silicone on the semi moons onthe head in correspondence with the camshaft.

8 N•m

8 N•m

- 34 -

Engine

B

Do not tighten the stand screws if the reac-tion springs are charged. Appropriately turnthe camshaft so that the stand springs ofwhich are to be tightened are uncharged andthat the cams are positioned on the baseradius.

Position the valve cap.Manually position the screws, thus tighten at 8 Nm.Place the adduction oil tube at the head greasing the O-Rings.

Dismounting cylinder head pieces

In order to carry out this procedure the following toolsare necessary:tool n° 800094796 to disassemble valvestool n° 800095179 to remove semi conestool n° 800094798 to take out rubber holdings

Each piece relative to the same valve (cup,spring, semi cone, etc.) must be reassembledonto the same valve from which it came off.

Remove the cylinder head as indicated the paragraph“cylinder assay removal”.

800095179

Engine

- 35 -

B

Valve removelA)Take out the cups (1) with the help of a magnet and

number them with a marker so as to reassemblethem in the same position.

B)Remove the tablets (2) of play adjustment with amagnet and place them inside the relative cup so asto reassemble them in the same position. To removethe semi cones (3) exclusively use tool n° 95179 soas to avoid bending the valves:

C)Assemble the head on tool n° 800094796D)Hammer on the superior disk with a rubber hammer

to unblock the semi conesE)Press the springs on the superior diskF)Take out the semi cones with a magnetG) Slowly release the disk pusher.

Then remove in the following order:A)SemiconesB)The 2 coaxial springs (4 and 5);C)If necessary remove the rubber holdings using tool

n° 800094798D)Remove the inferior disk more grazingly (6)E)Slide the valve out of the combustion chamber

800094796

1

- 36 -

Engine

B

800094798

Engine

- 37 -

B

Maintenance of the valve slot

Check the stroke surface [A] between the valve [B] andthe slot [C] : no traces of pitting or cracks must appear.Measure the external diameter [D] of the stroke surfaceon the valve slot.If this should appear to be too elevated it is possible torepair the slot.

External diameter of the stroke surface of the valveslot

Standard: exhaust 24,6 mm

inlet 28,6 mm

Measure the width of the stroke [E] with a varnishedgauge or with Prussian blue.If it should turn out to be too wide, too thin or irregularit will be necessary to repair it.

Thickness of the stroke surface of the slot

standard : exhaust, inlet 1 mm [E]

The repair must be carried out by milling the slots usingthe appropriate monocutting milling machines at 78°(1), 45° (2) and 17° (3).Ten proceed with the grinding of the valves and verifi-cation of the holding.

Remove the minimum quantity of material from theslot.Inlet max 0,5 mm (vertical)Exhaust max 0,5 mm (vertical)

Verify that there is no leakage filling the inlet andexhaust of the gas canalization.If so, check the quality of repair with Prussianblue.

When reassembling never use calibratedtablets of a thickness inferior to 1,6 mm.

+0,30

+0,30

+0,2-0,3

OPTIMALTOOWIDE

TOOTHIN IRREGULAR

- 38 -

Engine

B

Substitution of the valve slot

The following tools are necessary for this procedure:prick-puncher n° 800095319 for inlet slotprick-puncher n° 800095318 for exhaust slot

Proceed as follows:A)Remove the worn slots carefully milling them so as

not to damage the head lodgingB)Check the lodging diameter on the head and choose

the oversized valve slot considering that the assem-bling interference should be 0,10÷0,15 mm.

C)Valve slots are furnished with an increased replace-ment part of 0,03 mm on the external diameter.

D)Slowly and evenly heat the head at a max tempera-ture of 180°C and cool the new slots with dry ice.

E)Place the slots perfectly in frame into its lodging,using the special n° 800095319 prick-puncher(INLET) e n° 800095318 (EXHAUST)

F)Let cool and proceed with the milling of the slots andgrinding the valves referring to the following quo-tients:

Ø A 28,60

Ø S 24,6

[E] 1

0+0,3

0+0,3

+0,2-0,3

800095319 800095318

Engine

- 39 -

B

Valve guide check and maintenance

In order to carry out this procedure the following toolsare necessary:Control tampon n° 800095429Tampon n° 8000A2385

valve stem-valve guide play: 0,01÷0,03 mm inlet0,02÷0,04 mm exhaust

coupling limit : 0,08 mm inlet0,1 mm exhaust

internal guide Ø limit: 4,55 mm

Proceed with an accurate visual check of the valveguide.In order to determine the coupling wear between guideand valve stem it is necessary to measure the playusing a control tampon and micrometer.

The control tampon 800095429 (Ø 4,55)must not pass.

In the case of substituting the guide valveit ist is necessary to check and if neces-sary also substitute the valve.

Removal of the valve guide

After having removed the valves and rubber holdingsas described in the relative paragraph, continue as fol-lows:Slowly and evenly heat the cylinder head up to 100°.Using tampon n° 8000A2385 slide out the valve guide.Continue with a visual check of the slot to verify itsState.

NOTE

NOTE

800095429

8000A2385

- 40 -

Engine

B

Guide valve installation

Assemble an oversized valve guide as follows:

Oil the external valve guide surface.Slowly and evenly heat the cylinder head up to 150°.If necessary cool the valve guides with (N2) nitrogenliquid; or dry ice.Insert the valve guide using the special n° 8000A2385tampon up to the stroke and let rest until the tempera-ture has stabilized.Check to be sure the valve slides freely in the valveguide otherwise coat it with a 4,5 H7 reamer or broachN° 8000A2625.

Valve

The stem diameters must not fall below: 4,485-3/100 mm inlet4,475-3/100 mm exhaustThe width of the sealing surfaces should fall in therange 0.7 - 1.2 mm (see figure).Check to be sure that the stem and the surface in con-tact with the valve slots are in good condition. Notraces of pitting, cracking, deformations or traces ofwear should appear. Verify that the stem is perfectlyrectilinear.

Plane αα (coincidingaxial valves exhaust)

Plane ββ (coinciding axialvalves inlet)

Engine

- 41 -

B

Valve-guide valve coupling

Coupling play at assembly must be: 0,01 ÷ 0,03 mm inlet0,02 ÷ 0,04 mm exhaustThe maximum coupling limit permitted is even to 0,08 mm inlet0,10 mm exhaustIf a major play should result, substitute valve and valveguide.

Springs

Check to be sure that the free value of length is notinferior to the suggested limit and in such case substi-tute the springs:Internal spring L = 33,8 mm Service limit 33,3 mm

External spring L = 37,9 mm Service limit: 37,4 mm

Valve reassemblyA)Carefully degrease the guideB)Insert the inferior basement disk (6) and be sure that

it is in beat.C)Assembly the rubber holdings, always new, on the

valve guide using tool n° 800095581;D)Sprinkle the valve stem with oil.

800095581

- 42 -

Engine

B

Assembling the valve.

Insert in the order of:A)Insert the two coaxial springsB)Slide the semi cones into the superior disk slot and

thus place the disk on the springsC)Assemble the head on the disassembling valve tool

n° 800094796 and compress the spring with tool800095180 until the semi cones are inserted.

D)Using a rubber hammer strike a slight blow on thevalve so as to place the semi cones.

Before placing the semi cones be sure thatthe head is not resting on a plane in orderto avoid distorting the valve. Place it ontotwo bases which allow the valve to move.

E)Insert the tablet of the correct thickness and lubri-cate its surface

F)Make sure it easily turns in its slotG)Insert the cup after lubricating the slot

Insert the cylinder head as described in the paragraph“Head assay assembly”.

NOTE

800095180

Engine

- 43 -

B

Regulating valve playVerify that the spark plugs have been disassembled.

Should this procedure be carried out withthe head assembled on the motor, block thespark plug holes with clean rags and assem-ble plate n° 800094797 to avoid the piecesaccidentally falling into the chain distribu-tion opening.

A)Rotate the drive shaft until completely unwinding thesprings relative to the valves on which intervening(MSP in burst phase).

B)Measure valve play with a thickometer.

C)Calculate the D difference between the comparedplay and optimal play shown on the chart

D)Read the value of S thickness on the tablet;E)Choose a new tablet with an S+D thickness.

During reassembly never use a tablet with athickness less than 1,6 mm.

Inlet valve play Exhaust valve play

0,15 ÷ 0,24 mm 0,20 ÷ 0,29 mm

play

- 44 -

Engine

B

CYLINDER AND PISTON GROUP

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 8

Tighteningtorque

Thread blockers Medium

Engine

- 45 -

B

Removing cylinder and pistons

Remove the cylinder head and rubber connecting rodbetween the cylinder and water pump as described inthe relative paragraphs.Carefully slide out the cylinder group being careful notto damage the elastic strips.Work on one piston at a time to continue the removal.First remove the 2 pistons which are at the MSP androtate the drive shaft at 180° and disassemble the 2remaining pistons.Remove the elastic ring which blocks the plug to thepiston.Slide the plug off.Slide the piston off only after having marked the ceil-ing with a marker to reassemble it properly.Slide the gasket off between the cylinder and bed-plate.

- 46 -

Engine

B

Cylinder revision

Check to be sure that enclosures show no sign ofseizures with the pistons.Check piston ovalization in the following way:

A)Measure the nominal diameter of each cylinder ata distance of 20 mm from the superior edge asindicated in the figure.

B)Perpendicularly repeat the measurements to thepreceding ones.

C)Verify that the ovalization is inferior to 0,015 mm(wear limits).

In the case that not even one cylinder should pass thisverification, substitute the entire block, If the blockshould be substituted and if necessary also substitutethe pistons and elastic strips. The cylinder is markedwith a letter which indicates the class it belongs to: Aand B cylinders and A and B pistons exist which mustbe coupled with the same letter; the cylinder-pistoncoupling must be carried out between classes of thesame origin (A cylinder-A piston; B cylinder-B piston).

Piston revisionCarefully clean the piston ceiling from carbon residues.Continue with a careful visual check of the piston; nosigns of lines or other damage must appear.Measure the diameter of the piston at the portion indi-cated in the direction perpendicular to the piston pinaxle.In the case of excessive wear of one of the pistons,substitute it. The piston should belong to the sameclass of the cylinder selection.

Engine

- 47 -

B

Piston-cylinder coupling The cylinder-piston groups are furnished already cou-pled; if there should be an exchange of cylinders andpistons between them it would be necessary to pro-ceed surveying coupling plays.Measure the diameter of the (ND) pipe at 20 mmfrom the superior plane, as indicated on the sketch.The piston diameter must be measured at 8 mmfrom the shell base, in a perpendicular position to thepiston pin axle.These measurements must be carried out at a stabi-lized temperature of 20°.The play between piston and cylinder must fallbetween 0,038 e 0,067 mm.Maximum wear limit permitted 0,10 mm.

Piston pin revisionVerify that the piston pins show no lines or bluishcolours which indicate overheating.

Piston-pin couplingThe (S) play between piston pins and piston mustbe of 0,004÷0,012 mm in case the limit is exceeded itis necessary to substitute the piston pin and piston.The limited wear permitted is 0,03 mm.

- 48 -

Engine

B

Piston-pin connecting rod foot couplingPlay between piston pin and connecting rod footmust be of 0,015÷0,032 mm.

Maximum wear limit allowed 0,04 mm.

SegmentsVerify the absence of lines and traces of shrinkage oneach segment.Verify that the edge of the segment is well defined andfree in the segments.The spare pistons are furnished complete with seg-ments and piston pins.Whenever segment wear is noticeable it is recom-mended to change the pistons as well.

Segment-cylinder coupling Introduce the 5 mm segment under the head planebeing careful to position it well in “square” and to mea-sure the distance between the two ends of the seg-ment.The maximum play allowed between the ends of thering is the following for each segment:

SEGMENT N°1: 0,2 ÷ 0,4 mm; Maximum wear limit allowed 0,6 mm

INTERMEDIATE SEGMENT : 0,2 ÷ 0,4 mmMaximum wear limit allowed 0,6 mm

OIL SCRAPER : 0,2 ÷ 0,7 mmMaximum wear limit allowed 1,0 mm

SEGMENT Standard Wear limit

1° SP 0,8 0,75

2° SP 0,8 0,75

Oil scraper SP 1,5 1,38

-0,01-0,030

-0,02-0,03-0,08

Engine

- 49 -

B

Cylinder and piston assemblyThe segments must be assembled on the piston withthe writing Ne Top turned upwards and by following theoutline in the figure.Oil the connecting rod foot and piston pin.Assemble the internal ring on the pistonInsert the pistons complete with segments on the con-necting rods with the arrow facing the exhaustInsert the piston pins into the piston until beat.Assemble the external rings.

Before securing the piston pins with theblocking rings, cover the bedplate openingwith a clean rag to avoid any pieces fromfalling into the oil cup. Always use newblocking rings.

Assemble a new gasket between the cylinder and bed-plate.Position the clamps onto the pistons in the directionshown in the sketch.Oil cylinders and clamps.Position the two pistons 1 and 4 at the MSP turning thedrive shaft.First insert the two pistons at the MSP, thus rotate thedrive shaft at 180° to invert the piston positions and toinsert the two remaining ones.Insert the pistons by manually pushing down on thesegments.Proceed with maximum care since it concerns a verydelicate procedure due to the fragility of the segments.Make some turns with the unloaded drive shaft andcheck to be sure that the pistons move freely withoutforce.

3rd Bottom

3rd Spring

3rd Top

rdst

nd

stnd

- 50 -

Engine

B

CLUTCH

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 8 140 10

Tighteningtorque

Thread blockers Average

1 code 8000A2561 q.ty 72 code 8000A2562 q.ty 83 code 8000A2560 q.ty 24 code 8000A3379 q.ty 15 code 8000A3380 q.ty 1

Engine side

Engineside

Engine

- 51 -

B

The clutch release occurs using a postponing returngroup composed of a small thrust piston placed on theleft side of the motor and operated by a hydraulic sys-tem.This small piston pushes a command rod which makesthe disk pusher plate function.

Clutch disassembly

In order to carry out this function the following specialtool is necessary:

Utensil n° 800079015

Remove the 11 screws which fasten the clutch cap tothe bedplate.Remove the clutch cap together with the gasket whichwill be substituted during reassembly.

Remove the 4 disk pusher plate tightening screws (1)together with the relative springs (2).

800079015

1

2

- 52 -

Engine

B

Remove the disk pusher plate.

If the friction rod must be slipped off, it isimportant to replace it from the cylindricalside of the friction control (left side of theengine) in order to prevent the oil seal (1)from damaging. See the illustration on thefollowing page with the slot for the lubrica-tion facing towards the friction side.

Manually remove all of the attrition disks (3) that youcan.Subsequently straighten the nut washer.

Unscrew the nut using tool n° 800079015 to hold theclutch hup still and remove it.

Remove the washer (6) and friction bell (7).7 6

3

Engine

- 53 -

B

Remove the spacer (8) and shaving washer (9).

Disassemble the clutch block following the sequence inthe figure.

8 9

- 54 -

Engine

B

Clutch overhaulingCheck the rod for straightness and wear.

Check the friction plates for wear. The standard thick-ness is 3 mmMaximum allowed wear limit : 2,8 mm.No signs of burning, grooves or other damages areallowed.Replace the whole plates group even if only one isdamaged.

Put the plate on a table and check the deformation.The maximum limit of deformation is 0,1 mm.

Measure the length “L” of the springs with a gauge.Service limit: 57,9 mmReplace the springs exceeding the service limit.

Clutch reassemblyReposition the shaving washer (9) with the smallestdiameter facing towards the engine. Position the spa-cer (8), roller cage, friction drum and washer. Makesure the washer is positioned in front of the frictiondrum, since it was sheared and therefore has a sharpcorner and a rounded corner. Position the rounded cor-ner on the engine side.

Assemble the disk-holding hub by firstmounting the “5” piece (see FRICTION fig.),then the “4” spring with the smallest diame-ter facing towards the engine. Mount thedisks alternating the nine lined disks withthe eight smooth disks starting with a lineddisk with reduced track.

Attention: The first and last lined disks havea larger internal diameter.

Engine

- 55 -

B

8 9

- 56 -

Engine

B

It is recommended that a new safety washerand nut be used during reassembly.

Tighten the nut at 140 N•m using a medium thread-locking product and then bend the safety washer.Assemble the disk pusher plate tightening the screwswith springs as 10 N•m.Substitute the cap gasket.Aline the centering pins.Position the cap and manually bring screws close.Tighten the screws at 8 N•m.

140 N•m

10 N•m

8 N•m

Engine

- 57 -

B

GEAR AND GEAR CONTROL

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 140 8 8 6 25 (M8) 25

Tighteningtorque

Thread blockers Medium Medium Medium

- 58 -

Engine

B

Disassmbling gear groupRemove the clutch following the instructions in the rel-ative paragraph.Remove the clutch rod from the clutch end.Remove the 6 tightening screws from the gear cap.Using a rubber hammer, delicately beat on the primaryshaft from the clutch end holding a hand on the gearcap until it moves from the bedplate.

Slide the gear group out.

It is important to reassemble the friction rodfrom the cylindrical side of the friction con-trol (left side of engine) in order to preventthe oil seal from damaging (1). See the illu-stration on page 53 with the slot for the lubri-cation facing towards the friction side.

Engine

- 59 -

B

Gear commandDisassemble the gear command groupfollowing the order shown in the figure.Place the various components in anorderly way so as to facilitate reassem-bling.Check each component for wear ofirregular traces on its surface.Carefully check the following compo-nents.

Shift drumCheck the shift drum: no signs of wearon the grooves are allowed.Fork pin - groove clearance for newparts: 0,15÷0,35 mm. Wear limit: 0,65 mm.Groove width of a new drum: 7,05÷7,15mmWear limit: 7,35 mm. The new fork pin diameter is equal to6,8 ÷ 6,9 mmWear limit: 6,7 mm.Verify the working clearance betweenthe fork pin and the shift drum groove,measuring the dimensions with agauge.If the value exceeds the service limits,compare the standard value to choosethe parts to be replaced.

Verify the gear locker pawl free move-ment.Reassemble the various parts by actingin the opposite way.

Degrease accurately and applyMEDIUM THREAD BLOCKER toall the screws, before reassem-bly.Lock all the screws at a 8 N·mtorque but the screw 1, needing a25 N•m torque.

1

8 N•m

25 N•m

- 60 -

Engine

B

Primary and secondary shaft

Check the two shafts separate-ly so as to avoid confusion ofsimilar components.

Place the components in such a way asto facilitate the correct positioning dur-ing reassembly.

Engine

- 61 -

B

Gear group revisionIn order to carry out the following procedure the follow-ing special tool is necessary:

Motor simulation utensil n° 8A0094792

Disassemble the gear group from the motor andreassemble it on the special utensil n° 8A0094792motor simulator being careful to tighten the pinion fix-ing nuts with the separator that simulates the clutchhub.Check the condition of the front clutching teeth of thegears which must be in perfect shape and sharpedged. The neutral gears must rotate freely on theirshafts.All of the neutral gears must present a minimum axialplay of 0,10 mm.Verify the wear on the bearings present on the insideof the gear box.Verify the control quotas indicated onthe sketch in the figure.

Gear selection forksVisually inspect the gear selection forks to look forfolds or other damage.Every fork that appears damaged must be substitutedbecause it can cause difficulty when inserting a gearand causes sudden uncoupling under load. Check theplay of each fork using a thick meter in the groove of itsgear. I play is above 0,7 mm substitute the gear or forkin relation to service limit of each part.

Gear groove limit 5,6 mm Primary4,6 mm Secondary

Limite forcelle 4,65 mm Primary 5-6 gear3,65 mm Secondary 1-2, 3-4 gear

The fork must be able to move without force. Grippage of the gears must flow without impedimentsand without excessive attritions.

8A0094792

WITH 5 ENGAGED

WITH 6 ENGAGED

WITH 2 ENGAGED

WITH 2 ENGAGED

WITH 4 ENGAGED

WITH 1 ENGAGED

- 62 -

Engine

B

InstallationTo execute this operation you need thefollowing special tools:

n° 8A0094792 gearbox tool

Reassembly the various parts by actingin the opposite way.Install the 2 shafts on the n° 8A0094792engine simulation tool.Install a shift pedal and check the gearbox is correctly working.

Always install a new washerunder the pinion at reassem-bly. Carefully degrease thethreads before reassembly.

Tighten the pinion nut at 140 N•m usinga strong thread blocker. Turn the securi-ty washer again so as to avoid the acci-dental unscrewing of the pinion nut.

Engine

- 63 -

B

All the gears must be inserted and unin-serted without stumbling.In case of stumbling, verify that the axialplay has been correctly restored.With a thick meter verify that each gear-ing, once inserted presents a fork-pitplay equal to 0,2 ÷ 0,3 mm placing it onboth ends of the coupling.The fork must be free.Assemble the gasket on the internalend.

Before inserting the gear group into the bedplate veri-fy that a gear is inserted so as not to damage the neu-tral indicator switch.

Do not insert the gear group in neutral intothe bedplate.Insert the clutch rod.

- 64 -

Engine

B

ELECTRICAL COMPONENTS

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 10 25 10 22 12 6 8

Tighteningtorque

Thread blockers Medium Medium

Engine

- 65 -

B

Remove the pick-up from the phonic wheel.

Alternator- Removal:

Working on the left side of the motor, remove thethree alternators and the stiffening stirrup tighteningnuts.Slide the alternator out being careful not to let therubber torsions fall.

- Assembly:Grease the torsions and O-Rings.Insert the pallets together with the torsions.Manually bring the screws together, thus tightenthem at 25 Nm.

Starter motor

- Removal:Remove the two tightening screws (1).Slide the starter motor out, being careful not to dam-age the O-Rings on the shaft.Assembly:Reassemble the motor on the bedplate.Manually bring the two screws together (1), thustighten them at the prescribed coupling.

1

25 N•m

- 66 -

Engine

B

OIL PUMP

OIL Apply motor oil


GR Apply grease





Tighteningtorque


Engine

- 67 -

B

Remove the clutch and the gear as described in therelative paragraphs.Remove the seeger and the oil pump gearing.Remove the 3 tightening screws.Push the oil pump shaft from the gear end and slide theoil pump body from the clutch end.To disassemble the oil pump remove the externalscrews.Separate the various components as indicated in thefigure.

Visually check the components to besure that there are no lines of deforma-tions.In case one of the pieces should bedamaged, substitute it with a new one.Reassemble the oil pump in the reverseorder of assembly.Tighten the 3 screws at 8 N·m withMEDIUM THREAD BLOCKER carefullydegreasing them before reassembly.

- 68 -

Engine

B

WATER PUMP

OIL Apply motor oil


GR Apply grease





Tighteningtorque


Engine

- 69 -

B

Removing water pump

Work with cold motor.

Drain liquid.

A)Loosen the clamp and remove the coupling from thecylinder group,being careful not to damage it.

B)Remove the screws (1) which fasten the pump bodyto the bedplate.

C) Slide the pump out of the bedplate.

Disassembling water pump piecesAfter having extracted the pump fromthe bedplate disassemble the pump asfollows:A)Remove the tightening screws from

the pump body (1) and separate thelatter from the cap.

Be careful no to let the twocentering bushes fall (9).

B)Remove the two O-Rings (2)C)Remove the two seeger rings (3)D)Take the impeller out (4) from its shaft

(5) E)Separate the impeller (4) from its

shaft (5) by unscrewing.

During the following procedureuse the necessary precautionsso as not to get burned.

- 70 -

Engine

B

A)Heat the pump body (1) at 120°C.B)Remove the two bearings (6) with its relative space

(7).

C) Remove the seal ring.

Revision of water pump piecesVerify that each component does not show any wearsigns.In particular verify the flowness of the bearings and theO-Ring conditionVerify that the impeller does not show signs of givingaway or slits.Verify the absence of excessive play between theimpeller shaft and bearings.In case of wear of one of the components substitute it

Reassembling water pump parts

During the following procedure use the nec-essary precautions so as not to get burned

A) Insert the oil seal (8). Always use a new oil seal andinsert it with the punch provided. Apply mastic as agasket.

Engine

- 71 -

B

B)Insert the two bearings (6) with the relative spacer.

C) After waiting for the pump body to cool, insert theseal and the counterface degreased in alcohol. Theninsert the shaft with the impeller and rotating sealwithout touching the charcoal with oily hands.

D)Insert the two seeger rings (3)E)Insert the two O-Rings (2)

Be careful not to let the two centering bush-es fall (9).

F) Insert the two pump body tightening screws (1) andunite the latter to its cap.

Water pump reassembly A)Insert the pump on the bedplate being very careful

not to damage the O-Ring on the pump bodyB)Insert the screws (1) which fix the pump body onto

the bedplateC)Install the coupling with its clamp onto the cylinder

group, being careful not to damage it.

- 72 -

Engine

B

STARTING

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 10 55 25

Tighteningtorque

Thread blockers medium strong medium

Engine

- 73 -

B

Free wheel startingRemove the clutch and gear indicated in the relativeparagraphs. Slide out the intermediate starting gearpin, first disassemble the pin-blockage plate.Slide the intermediate gear.Slide the alternator flange and generator shaft out.If necessary disassemble the male torsion from thegenerator using tool 800094794 to unscrew the nut.Disassemble the generator command shaft using theappropriate 800094795 blockage tool to unscrew thescrews.Disassemble and verify the free wheel state.Reassemble the free wheel with the seeger turnedtowards the inside; to facilitate the procedure, insertthe part where the seeger is opened last. Verify thatthe free wheel only turns clockwise.Assemble the group on the tool 800094795 and blockthe screw with a dynamometric key at 25 N·m andMEDIUM THREAD BLOCKER.Reassemble the male torsion joint on the generatortightening nut with STRONG THREAD BLOCKER at55 N·m.Turn the oil drainage hole present on the flange down-wards, but only after having completely inserted it intothe engine to prevent the O-ring from damaging.Tighten the screws with MEDIUM THREAD BLOCK-ER at 10 N·m.Insert the starting gear with the smaller toothing turnedinwards from the gear end.Insert the pin from the clutch end.Assemble the pin-blockage plate fastening the screwwith MEDIUM THREAD BLOCKER.

Neutral switchThis component does not call for maintenance. In thecase of a malfunction, substitute the switch. Whenreassembling it insert the switch with the help of a tubekey and tighten at 10 N·m.

800094794

800094795

- 74 -

Engine

B

MOTOR SHAFT

A* B C D E F G H I J KN·m 25

Tighteningtorque


OIL Apply motor oil


GR Apply grease




* See text

Engine

- 75 -

B

Disassembling connecting rodRemove the driveshaft following the suggested proce-dure.Position the shaft with the connecting rod downwards.Work on each connecting rod separately.Loosen the two screws that tighten the foot of the con-necting rod and the head of the rod.Remove the two screws that sustain the connectingrod stem. Move the two motor drive shaft parts away.

Reassemble each connecting rod beforeworking on the next one.

Removing semi bearings Disassemble the connecting rod following the suggest-ed procedure.Unscrew the screws and remove the semi bearingsfrom the foot and head of the connecting rod.

Coupling semi bearings-connecting rod pinIf no substitutions have been made it is sufficient toverify the connecting rod measurement and its pinsand refer to the chart included, choose the semi bear-ings according to the colour.The measurement has to be carried out on the princi-pal axle of the stem, after having tightened at 35 N·m.If substitution of one or more parts is necessary, it issufficient to follow the indications of the letter indicatingthe class that the connecting rod and bushing belongto, indicated on them.

Assembling semi bearingsInsert the half-bearings at the foot and head of the con-necting rod.• Degrease the screws and the connecting rod.• Apply oil only to the internal thread.• Fasten and make sure the length of the screws is

between 0.20 mm and 0.22 mm with a minimum tor-que of 50 N·m

• Only use worked screws with measuring area sup-plied as spares.

Always use new screws, even with the used con-necting rod. Ensure that the comparator feelers only come intocontact with the worked surfaces.

SELECTION TABLE FOR F4 CONNECTIN ROD

FUNCTIONING PLAY 0,036/0,061

CONNECTING ROD HEAD DIAMETER

A 38,114 B 38,12338,122 38,130

CONNECTING ROD PINDIAMETER

A 34,981 1,540/1,545 1,544/1,54934,988 BLUE YELLOW

B 34,989 1,536/1,541 1,540/1,54534,997 RED BLUE

NOTE

Worked surfacesto be measured

- 76 -

Engine

B

BEDPLATE

A B C D E F* G H I J KN·m 10 25 10 10+60° 22 8 14 25 30

Tighteningtorque

Thread blockers Medium Medium Medium Medium

OIL Apply motor oil


GR Apply grease




* See text.

Engine

- 77 -

B

CAPS

OIL Apply motor oil


GR Apply grease




A B C D E F G H I LN·m 10 25 10 8 35

Tighteningtorque

Thread blockers Medium Medium

- 78 -

Engine

B

Oil sump

Disassembling and reassemblingRemove the oil sump by unscrewing the 6mm fixingscrews.Always substitute the gasket when reassembling.Check the condition of the oil intake filter and makesure that it is free of cracks or clefts; clean it by usingcompressed air at a low pressure, blown from inside tooutside.

Remove the oil filter support by unscrewing the relativescrew.

Check that oil pressure adjusting valves (A) and (B)are also free of cracks or clefts, verifying that they arein good condition; remove them, if necessary.Clean with compressed air blown from inside to out-side.Once the check has been carried out, reassemblethem on the base as shown in the figure.

B A

Engine

- 79 -

B

Position the gasket and move the screws close manu-ally.Tighten the sump screws to 10 Nm.

10 N•m

- 80 -

Engine

B

DisassemblyRemove the oil filter with the relative support.Remove as follows as indicated in the relative para-graphs:

A) The headB) The cylinder groupC) The pistonsD) The clutchE) The gear

Remove:F) The size 6 screws including the one for the blow-by

cap.

Do not forget to unscrew the screw insidethe carter indicated with the number 17 inthe figure. At the same time, remember tounscrew the screws positioned on theupper part of the base under the blow-bycover.

G) The size 8 screws.

All the screws are of the same length orvisually different; it is therefore impossibleto confuse them during reassembly.

NOTE

NOTE

Engine

- 81 -

B

H)Separate the two carters (1 and 2) by manipulatingthe protrusions.

I) If necessary remove the bearings (3).

L) Slide the motor shaft out.In the event that the bushings should be temporarilyremoved (4) it is a good idea to identify the bearingnumber and its carter with a number using a marker.For example the bushing removed from the n°1bearing of the superior carter (starting from the left)will be identified by the mark S1.For the couplings refer to the groups they belong toshown on the chart.

SELECTION TABLE FOR F4 BEARINGS

FUNCTIONING PLAY 0,012/0,038

BEDPLATE SLOT DIAMETER

A 38,103 B 38,11238,111 38,119

BENCHPIN

DIAMETER

A 34,981 1.546/1,551 1,550/1,55534,988 BLUE YELLOW

B 34,989 1,542/1,547 1,546/1,55134,997 RED BLUE

1

2

3

- 82 -

Engine

B

RevisionOnce you have disassembled the motor shaft and incase there should be any doubt substitute the benchbushings as well as the connecting rod.Verify the motor shaft wear tolerance.The function play of the bench bearings must bebetween 0,012÷0,038 mm. Service limit is 0,06 mm.The function play of the connecting rod bearing mustbe between 0,036÷0,061 mm.With a service limit of 0,08 mm.

ReassemblyCarefully degrease and clean from any paste residues Position the bushings into the carter without lubricat-ing.

After having positioned them put oil on each bush.

Engine

- 83 -

B

Laterally lubricate the n° 5 support as it carries out thefunction of the motor shaft centering.

Put the new cap on the right side after having put thesilicone type paste on the cap’s surface, between capand carter bearing.

Assembly the motor shaft.

- 84 -

Engine

B

Verify with a thick meter that the motor shaft has anaxial play of 0,2 mm as regards the bench bearings.In case there should be different values contact themanufacturer.

Reassemble the bearing on the inferior semi carterwith the locks facing each other and turned inward thebedplate.

Be sure that the centering bushes are installed on theinferior semi carter. Spread a layer of the 1215THREEBOND type garnish on the stroke points of thetwo semi carters.Couple the two semi carters carefully beating themwith a plastic hammer until completely closed.

Engine

- 85 -

B

Insert the twelve size “8” screws (marked with the num-bers 1 to 12) and tighten them at 10 N·m + 60° whilethe remaining M8 are tightened at a torque of 25 N·m.Tighten the M6 screws at 10 N·m.

Tighten all the screws inversely to the orderthey were disassembled.

- 86 -

Engine

B

1

22

Then, remove the oil head delivery conduit by remo-ving the lower and upper fixing screws respectively.

Unscrew the three screws (2) and remove them; thenremove the special screw (1) placed on top left.

LUBRICATION COMPONENTS:OIL TUBING SUPPORT PLATE

Disassembling and reassemblingTo remove the oil tubing support plate, the oil filter sup-port should be removed first, as described in the “Oilsump” paragraph.

Engine

- 87 -

B

1

40 N•m

LUBRICATION COMPONENTS:OIL FILTER SUPPORT

ReassemblingClean all the surfaces accurately and check the sealrings on the oil filter support screw as well as the O-rings for wear; substitute them, if necessary.Grease both the seal rings and the O-ring and positionthem in their seats respectively, as shown in the figure.

Position the filter support on the base; as per guidingand centering it refer to the special screw (1) for fixingthe oil cooler union plate placed on top left.

Once the support has been positioned, tighten the oilfilter support screw to a clamping torque of 40 Nm.Assemble the short end of the oil filter union byapplying medium thread blocker (Loctite 243) and tigh-tening to a clamping torque of 30 Nm.

- 88 -

Engine

B

When reassembling, clean the surfaces accurately,and if the nipples have been removed from the oiltubing support plate, reassemble them by alwaysinserting new copper washers between the nipple andthe support plate.

Screw the cylindrical end of the unionsverifying that the conical side of each unionhas been left free.

Apply a medium thread blocker (Loctite 243) and tigh-ten the nipples to a clamping torque of 30 Nm.

Verify the three O-rings placed in the back part of the oil tubing support plate for wear and substitute them, ifnecessary.When reassembling, grease the O-rings before reas-sembling the plate.

Position the plate on the base and fix it by using thethree screws (2) and the special screw (1), tighteningthem to a clamping torque of 10 Nm.

Take care that the special screw positioning(1) follows the one shown in the figure.

2

1

30 N•m

10 N•m

Engine

- 89 -

B

10 N•m

10 N•m

Verify the O-rings placed on the oil head delivery con-duit for wear and substitute them, if necessary.

When reassembling, grease both O-rings and positionthe upper part of the conduit in the seat arranged withinthe head and the lower part of the counduit in the seatarranged in the oil tubing support plate.

Tighten the upper fixing screw of the oil head deliveryconduit to a clamping torque of 10 Nm.

Carry out the same operation for the lower fixing screwby tightening it to a clamping torque of 10 Nm.

- 90 -

Engine

B

REPLACEMENT OF OIL FILTER

Take out the oil filter from the new engine oil filter kit.

- Toyo Roki oil filter kit: Part code 8000A3702

Only use original components of MV Agusta.

Take a new rubber clamp from the motor’s oil filter kitand place it on the filter as shown in the figure to theleft.

Only use new parts.

Let the rubber clamp slide until it comes into contactwith the back ring of the oil filter (see figure to theright).

Lubricate the gasket on the filter with engine oil.

Engine

- 91 -

B

Insert the filter in its seat.

Turn the filter manually until the gasket is into slightcontact with the machined surface.

Tighten the filter using the appropriate tool and a tor-que wrench.

- TOYO ROKI oil filter:

FACOM D. 139 toolPart code 8000A4317

Oil filter torque wrench:24 N·m

After having tightened the filter, take out the clamp forengine oil filter and its screw from the new oil filter kit.

Only use a new clamp.

Insert the clamp and slide it until it brings in contactwith the oil filter back ring.

24 N•m

- 92 -

Engine

B

2 m

m

Place the clamp lock at a range of 2 mm from thescrewhead on the supporting plate of oil cooler pipes.

Tighten the screw of the clamp until it comes into con-tact with the filter, without tightening.

Mark the screw position drawing a line by a felt-tip bothon the screw and on the clamp.

Make the last tightening of the screw getting it perform2 turns and 1/4 further the position marked previously.

-1÷1,5 mm

Once completed the assembly, ensure that the clamplock of the engine oil filter is at a range between 1 and1.5 mm from the screwhead on the supporting plate ofoil cooler pipes. Check any leakages from oil filter.

Mark the position of the definite tightening of the screwusing a felt pen, both on the filter and the band faste-ner. Trace a reference mark also on the band fastenerand the relative screw, with the object of eventuallychecking any slackening of the screw.

Do not use the oil filter as a point of grip orcontact.

Engine

- 93 -

B

1

Disconnect the radiator-engine anchoring rod (1) posi-tioned on the left side

Remove the oil radiator moving it from right to left inorder to release the support peg inserted in the rubberbulb support (1) on the right side.

1

LUBRICATING COMPONENTS: OIL RADIATOR

DisassemblingRemove the engine/ radiator support fixing screw pla-ced on the left side.

This figure and the next ones show anengine assembly which the water radiatorhas been removed from; but the describedoperations can be performed also whenthe radiator is assembled.

N.B.

- 94 -

Engine

B

ReassemblingInsert the support peg in the support (1) on the rightside making the oil radiator move from left to right.

1

Connect the engine/radiator anchor rod (1) on the leftside.

1

Put the radiator/engine support on the left side againand secure it tightening the screw.

Engine

- 95 -

B

If the pipes and connectors were removedfrom the radiator, replace them carefully byplacing a wrench on the radiator to preventthe connectors of the radiator from tearing.Lubricate with threading of the connector withengine oil. Tighten the pipes and connectorsat the prescribed torque.

Reconnect the oil delivery and return pipings with the nipplesof the oil pipings support flange lubricating previously the nip-ple threads placed on it by using engine oil.

Lubrificate using engine oil

Tighten the pipe fixing nuts to the radiator to the pre-scribed torque wrench.

Torque wrench setting: 18 ÷ 20 N•m

18 ÷ 20 N•m 18 ÷ 20 N•m

COLORE COPERTINA PANTONE BLU 289Ghiera, scritta ”MV AGUSTA BRUTALE 910 S” e ombra, argento lito

8A00A6440Part No. Edition No. 1

mv agusta 910 engine workshop manual

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